Multilayer protective cover including nonwoven material

ABSTRACT

Methods of making a protective cover. According to one method, a composite sheet is formed by providing a substrate formed from a nonwoven material having a puncture resistance exceeding 500 N, the substrate having a first surface and a second surface, disposing a first layer of plastic film on the substrate first surface and a second layer of plastic film on the substrate second surface. The composite sheet has a first end, a second end, a first lateral edge, a second lateral edge, and an axis extending between the first lateral edge and the second lateral edge. The method also includes folding the composite sheet about the axis to bring the first end of the composite sheet proximate the second end of the composite sheet and define a partially enclosed space having an opening proximate the first and second ends of the composite sheet.

PRIORITY CLAIM

This application is a divisional application of co-pending U.S.application Ser. No. 16/684,202, entitled “Multilayer Protective CoverIncluding Nonwoven Material,” filed on Nov. 14, 2019, which is reliedupon and incorporated by reference herein in its entirety for allpurposes.

TECHNICAL FIELD

Embodiments of the present invention generally relate to the field ofpackaging supplies. More particularly, certain embodiments of thepresent invention relate to a protective cover used to protect objectsfrom damage that may occur during transport and handling. In certainembodiments, the protective cover may have a multilayer structureincluding a layer of nonwoven material.

BACKGROUND

Furniture and other objects that are transported to and from variousplaces, including between manufacturers, wholesalers, retail sellers,and customers, can be damaged during transport. For instance, suchobjects may be subject to abrasion from contact with other objects beingtransported, contact with a shipping container, truck, or trailer, or asa result of handling. Thus, it is known to provide protective coveringsfor objects to be transported and handled.

The foregoing discussion is intended only to illustrate various aspectsof the related art in the field of the invention at the time and shouldnot be taken as a disavowal of claim scope.

SUMMARY

Presently available protective coverings for objects during transportand handling suffer from numerous drawbacks. Among other things, suchprotective coverings are often rubbed through during transport,particularly where transported objects are subject to vibration, leadingthe objects to be abraded, dented, scratched, etc. Further, suchprotective coverings have little or no puncture resistance, whichlikewise can lead to covering failure during transport and handling.Additionally, some coverings are made on an “as-needed” basis, forexample just prior to an object being wrapped in the covering (e.g., ona warehouse floor). The process of making these coverings requires theuser to perform a series of steps. Such multi-step processes requireadditional time, waste material, and decrease productivity.

For example, it is known to provide a protective covering in athree-step process. At the first step, a thin polyethylene sheet or bagis placed over a piece of furniture, e.g., as a dust cover. At thesecond step, corrugated cardboard pieces are placed in one or morelocations to shield against abrasion. For instance, cardboard trays maybe placed on the “top” and “bottom” ends of a sofa (i.e., when the sofais stood vertically on one end for transport). At the third step, apolyethylene sheet or bag that is thicker than the sheet or bag appliedin the first step is secured over the first bag and cardboard. Again,though, this type of covering is subject to failure due to thepolyethylene bags being rubbed through and because the covering lackssignificant puncture resistance.

In contrast, various embodiments of the present invention provide coversfor objects that have superior puncture resistance. Various embodimentsalso provide covers which may be “ready to use,” in that a user simplyneeds to take a bag, wrap an object in the bag, and secure the bag(e.g., with tape or other adhesive), as opposed to having to first makethe cover prior to wrapping the object. In some embodiments, aprotective cover may comprise a multilayer structure having layers ofplastic film disposed on either side of a layer of nonwoven material.Additionally, in some embodiments, one or more end caps, which may alsobe formed of a plastic film, may be disposed on one of the plastic filmlayers in locations such that, when the cover is placed on an object,the end cap(s) are disposed over one more portions of the object thatare likely to be damaged or abraded during transport and handling.

According to one embodiment, the present invention provides a method ofmaking a protective cover. The method comprises forming a compositesheet by providing a substrate formed from a nonwoven material, thesubstrate having a first surface and a second surface opposite the firstsurface; disposing a first layer of plastic film on the substrate firstsurface, wherein the first layer of plastic film has a first thickness;disposing a second layer of plastic film on the substrate secondsurface, wherein the second layer of plastic film has a second thicknessthat is greater than the first thickness; and disposing at least oneplastic film end cap on an exterior surface of the second layer ofplastic film, wherein the at least one plastic film end cap has a thirdthickness that is greater than the first and second thicknesses. Thecomposite sheet has a first end, a second end, a first lateral edgeextending between the first and the second end, a second lateral edgeextending between the first end and the second end, and an axisextending between the first lateral edge and the second lateral edge.The method further comprises folding the composite sheet about the axissuch that the first end of the composite sheet is proximate the secondend of the composite sheet. Also, the method comprises securing theportion of the composite sheet extending between the first end and theaxis to the portion of the composite sheet extending between the secondend and the axis to define a partially enclosed space having an openingproximate the first and second ends of the composite sheet.

In accordance with another embodiment, the present invention provides amethod of making a protective cover. The method comprises forming acomposite sheet by providing a substrate formed from a nonwovenmaterial, the substrate having a first surface and a second surfaceopposite the first surface, disposing a first layer of plastic film onthe substrate first surface, and disposing a second layer of plasticfilm on the substrate second surface. The nonwoven material has apuncture resistance exceeding 500 N. The composite sheet has a firstend, a second end, a first lateral edge extending between the first andthe second end, a second lateral edge extending between the first endand the second end, and an axis extending between the first lateral edgeand the second lateral edge. The method also comprises folding thecomposite sheet about the axis to bring the first end of the compositesheet proximate the second end of the composite sheet and define apartially enclosed space having an opening proximate the first andsecond ends of the composite sheet.

According to yet another embodiment, the present invention provides amethod of making a protective cover. The method comprises forming acomposite sheet by providing a substrate formed from a nonwovenmaterial, the substrate having a first surface and a second surfaceopposite the first surface, disposing a first layer of plastic film onthe substrate first surface such that at least a portion of the firstlayer of plastic film is slidable relative to the substrate firstsurface, and disposing a second layer of plastic film on the substratesecond surface such that at least a portion of the second layer ofplastic film is slidable relative to the substrate second surface. Thecomposite sheet has a first end, a second end, a first lateral edgeextending between the first and the second end, a second lateral edgeextending between the first end and the second end, and an axisextending between the first lateral edge and the second lateral edge.The method also comprises folding the composite sheet about the axis toalign the first end of the composite sheet with the second end of thecomposite sheet and define a partially enclosed space having an openingproximate the first and second ends of the composite sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described some example embodiments in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a plan view of a sheet of composite material in accordancewith an embodiment of the present invention;

FIG. 2 is a cross-sectional view taken along the line 2-2 in FIG. 1 ;

FIG. 3 is an enlarged schematic cross-sectional view taken along theline 3-3 in FIG. 1 ;

FIG. 4 is a plan view of the composite sheet of FIG. 1 wherein thecomposite sheet has been folded about an axis according to an embodimentof the present invention;

FIG. 5A is a front elevation view of the composite sheet of FIG. 4wherein portions of the folded composite sheet have been spaced apartrelative to one another to define an opening;

FIG. 5B is an enlarged cross-sectional view taken along the line 5B-5Bin FIG. 4 ;

FIG. 6 is a perspective view of a protective cover formed from acomposite sheet in accordance with an embodiment of the presentinvention disposed above a piece of furniture;

FIG. 7 is a perspective view of the protective cover of FIG. 6 after ithas been placed over the piece of furniture;

FIG. 8 is a perspective view of the bottom side of the protective coverof FIG. 6 after it has been placed over the piece of furniture;

FIG. 9 is a perspective view of several different objects that have beencovered with a protective cover in accordance with an embodiment of thepresent invention; and

FIG. 10 is a flow chart illustrating operations of a method ofmanufacturing a protective cover in accordance with an embodiment of thepresent invention.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof embodiments of the present invention.

DETAILED DESCRIPTION

Reference will now be made in detail to presently preferred embodimentsof the invention, one or more examples of which are illustrated in theaccompanying drawings. Each example is provided by way of explanation ofthe invention, not limitation of the invention. In fact, it will beapparent to those skilled in the art that modifications and variationscan be made in the present invention without departing from the scope orspirit thereof. For instance, features illustrated or described as partof one embodiment may be used on another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

As used herein, terms referring to a direction or a position relative tothe orientation of a protective cover, such as but not limited to“vertical,” “horizontal,” “upper,” “lower,” “front,” or “rear,” refer todirections and relative positions with respect to the cover'sorientation in its normal intended operation, as indicated in theFigures herein. Thus, for instance, the terms “vertical” and “upper”refer to the vertical direction and relative upper position in theperspectives of the Figures and should be understood in that context,even with respect to an apparatus that may be disposed in a differentorientation. The term “substantially,” as used herein, should beinterpreted as “nearly” or “close to”, such as to account for design andmanufacturing tolerances of the apparatus.

As used herein, the term “nonwoven” refers to textile structuresproduced by bonding or interlocking of fibers, or both, accomplished bymechanical, chemical, thermal, or solvent means, including combinationsthereof. The term “nonwoven” as used herein does not include foamsformed of plastic materials. As used herein, the term plastic filmrefers to a relatively thin, continuous polymeric material comprisingone or more synthetic or organic polymers, including polyvinyl chloride,nylon, polyethylene, polypropylene, polyurethane, and/or polyester,having a thickness up to and including about 20 mil (0.5 mm). Plasticfilms as used herein may be thermoplastics, and they may comprise one ormore of the foregoing polymers in various embodiments. Finally, as usedherein, the terms “sheet” and “layer” can include one or more sheets orlayers of material and may include one or more materials in each sheetor layer.

Turning now to FIGS. 1-3 , FIG. 1 is a plan view of a sheet of compositematerial 100 in accordance with an embodiment of the present invention.FIG. 2 is a cross-sectional view taken along the line 2-2 in FIG. 1 .FIG. 3 is an enlarged, schematic cross-sectional view taken along theline 3-3 in FIG. 1 .

In the illustrated embodiment, the composite sheet 100 comprises a firstend 102, a second end 104, a first lateral edge 106 extending betweenthe first and second ends 102, 104, and a second lateral edge 108extending between the first and second ends 102, 104. Composite sheet100 may also comprise an axis 110 extending between the first lateraledge and the second lateral edge. In that regard, composite sheet 100may define a first panel 112 and a second panel 114 about axis 110.First panel 112 may extend between first end 102 and axis 110 andbetween first lateral edge 106 and second lateral edge 108. Thus, thefirst and second lateral edges of panel 112 may be the respectiveportions of first lateral edge 106 and second lateral edge 108 thatextend between first end 102 and axis 110. Second panel 114 may extendbetween second end 104 and axis 110 and between first lateral edge 106and second lateral edge 108. The first and second lateral edges of panel114 may be the respective portions of first lateral edge 106 and secondlateral edge 108 that extend between second end 104 and axis 110.

As those of skill in the art will appreciate, although the compositesheet 100 is illustrated as being a quadrilateral that is rectangular inshape, this is not required in all embodiments. Rather, composite sheet100 may be provided having any shape (e.g., circular, semi-circular,square, triangular, parallelogram, rhombus, etc.) suitable for beingformed into a protective cover for an object. Additionally, in variousembodiments, axis 110 need not be centered relative to first end 102 andsecond end 104 in various embodiments. Axis 110 may be spaced closer toend 102 in some embodiments and closer to end 104 in other embodiments.Correspondingly, first panel 112 and second panel 114 may differ in sizein various embodiments, although as shown first panel 112 and secondpanel 114 are approximately the same size.

With specific reference to FIG. 2 , in one embodiment, composite sheet100 comprises a substrate, or layer, 120 formed of a nonwoven material.Substrate 120 comprises a first surface 122 and a second surface 124opposite the first surface 122. Additionally, composite sheet 100 inthis embodiment comprises a first layer 126 of plastic film that may becoupled with, disposed on, overlaid on, or adjoining the first surface122 of substrate 120. Further, composite sheet 100 in this embodimentalso comprises a second layer 128 of plastic film. Second layer 128 maycomprise an interior surface 130 coupled with disposed on, overlaid on,or adjoining second surface 124 of substrate 120 and an exterior surface132. In some embodiments, more than one substrate 120, first layer 126,and/or second layer 128 may be provided. As discussed in greater detailbelow, in various embodiments, a third layer 134 of plastic film may becoupled with, disposed on, overlaid on, or adjoining exterior surface132 of second layer 128. In other embodiments, however, third layer 134is not required.

Although the cross-sectional view of FIG. 2 is taken across first panel112, in the illustrated embodiment, first panel 112 and second panel 114are shown as being part of a single composite sheet 100, and thus eachof first panel 112 and second panel 114 comprise the same multilayerstructure. However, this is not required in all embodiments. Indeed, insome embodiments, first panel 112 and second panel 114 may be separatefrom one another until coupled together as described elsewhere herein.Additionally, in some embodiments where first and second panels 112, 114are not separate, panels 112, 114 may have the multilayer structuredescribed above, but composite sheet 100 may have a different structure(comprising one or more layers) around axis 110. Further, in someembodiments, each of the respective layers 120, 126, 128 in each panel112, 114 may be formed of the same material. However, in otherembodiments, one or more of the respective layers 120, 126, 128 in eachpanel 112, 114 may be formed of different materials, or the samematerial with different characteristics. For example, in variousembodiments, the respective layers 120 of nonwoven material in eachpanel 112, 114 may be formed of the same nonwoven material or may beformed of a different nonwoven material, or the same nonwoven materialbut each having a different weight.

In various embodiments, the peripheral dimensions of composite sheet 100may be selected to facilitate creation of a protective covering ofdesired size to cover a given type of object, as described in greaterdetail herein. Thus, the peripheral dimensions of composite sheet 100will vary in various embodiments. In some example embodiments, theperipheral dimensions of composite sheet 100 may be about 110″ (alonglateral edges 106, 108) by 80″ (along first and second ends 102, 104);about 110″ (along lateral edges 106, 108) by 100″ (along first andsecond ends 102, 104); about 110″ (along lateral edges 106, 108) by 120″(along first and second ends 102, 104); about 110″ (along lateral edges106, 108) by 140″ (along first and second ends 102, 104); or about 110″(along lateral edges 106, 108) by 160″ (along first and second ends 102,104).

Although as shown in FIGS. 1-3 layers 120, 126, and 128 may be the samesize, or have the same peripheral dimensions or area, that is notrequired in all embodiments. In addition to small differences in sizingthat may occur as a result of tolerances during manufacturing, it isalso specifically contemplated that any of layers 120, 126, and 128 mayhave different size and/or peripheral dimensions or area than any otherlayer 120, 126, 128. For instance, in some embodiments, layer 120 mayhave smaller peripheral dimensions than layers 126, 128. In someembodiments, layer 128 may have larger peripheral dimensions than bothlayers 120, 126, such that layer 128 provides additional material thatmay be used in wrapping an object. Those of skill in the art willappreciate that all other such variations in dimensions are within thescope of the present invention.

As noted above, substrate 120 may be a nonwoven material. In someembodiments, substrate 120 provides qualities of flexibility, abrasionresistance, cushioning, and puncture resistance for composite sheet 100.In one embodiment, substrate 120 may have a puncture resistanceexceeding about 500 Newtons. In some embodiments, substrate 120 may havea puncture resistance exceeding about 1000 Newtons. In still otherembodiments, substrate 120 may have a puncture resistance exceedingabout 1300 Newtons. In this regard, as used herein, the term punctureresistance refers to a value obtained based on testing according to ASTMD6241, AS 3706.4, or another test employing the California BearingRatio. Further, in various embodiments, substrate 120 may have a weightbetween about 4.5 oz/yd² and 11 oz/yd². In some embodiments substrate120 may have a weight of about 5.3 oz/yd². In various embodiments,substrate 120 may have various thicknesses corresponding to the abovecharacteristics. Those of skill in the art are familiar with and canprovide nonwoven fabrics and materials having such puncture resistancesand weights that are suitable for use in protective coverings forobjects being transported.

For instance, in various embodiments, substrate 120 may be analogous tothe DuraSpun® polyester spunbond nonwoven Type 011/180-02 offered byJohns Manville of Denver, Colo. However, those of skill in the art willappreciate that embodiments of the present invention are not limited tospunbond/spunlaid nonwovens or to nonwovens made from polyester. Forexample, as noted above, nonwovens within the scope of the presentinvention also include staple nonwovens, and they may be bonded viamachine needling (“needlepunched”), melt blowing, chemical bonding,and/or thermal bonding, among other methods.

Plastic film layers 126 and 128 may comprise a variety of materials andthicknesses within the scope of the present invention. In someembodiments, plastic film layers 126, 128 may be or comprisepolyethylene film, but that is not required in all embodiments. Invarious embodiments, plastic film layers 126, 128, may have thicknessesbetween about 0.5 mil and about 6 mil. In one embodiment, the firstlayer 126 has a first thickness, and the second layer 128 has a secondthickness that is greater than the first thickness. For instance, invarious embodiments, first layer 126 may have a thickness less thanabout 3 mil, and second layer 126 may have a thickness between about 2.5mil and 6 mil. In one example embodiment, first layer 126 has athickness of 1 mil, and second layer 128 has a thickness of 2.5 mil. Insome embodiments, second layer 128 may be equivalent to 3 milpolyethylene film but have a thickness of 2.5 mil. In another exampleembodiment, first layer 126 has a thickness of 0.5 mil, and second layer128 has a thickness of 3 mil. In still other embodiments, first layer126 and second layer 128 may have the same thickness.

In various embodiments, first layer 126 may be considered “high slip”plastic film, such that it is less likely to abrade a covered objectthrough contact. Further, in various embodiments, either or bothsurfaces of second layer 128 may be corona treated, for instance toreduce the surface energy of second layer 128 and to facilitate theprocess of wrapping an object in a protective covering. In that regard,where second layer 128 is corona treated, wrapping tape and otheradhesives may better adhere to second layer 128. Second layer 128 may becorona treated either prior to or during manufacture of composite sheet100. Those of ordinary skill in the art are familiar withcorona-treatment processes for plastic films, including, for example,the corona treatment systems offered by Enercon Industries Corporationof Menomonee Falls, Wis.

With reference now to FIG. 3 , in various embodiments first plastic filmlayer 126 and second plastic film layer 128 may be coupled with (e.g.,sealed to) all or a portion of substrate 120. For instance, in theillustrated embodiments, plastic film layer 126 and plastic film layer128 are sealed to substrate 120 at one or more locations proximate firstend 102. (Although FIG. 3 illustrates a cross-section across first end102, it will be appreciated that the same arrangement may be provided atsecond end 104 in various embodiments.) For example, sealing of firstlayer 126 with substrate 120 may occur via a pressure sensitive adhesive136, and sealing of second layer 128 with substrate 120 may occur viapressure sensitive adhesive 138. Adhesives 136, 138 may extend in a thinline along the length of first end 102 (and second end 104), or it mayextend along only a portion of such length. Likewise, adhesives 136, 138may be provided in a thin continuous line or in any suitable pattern(e.g., a series of dots). Those of ordinary skill in the art arefamiliar with suitable adhesives for this purpose. Also, in variousembodiments, either or both of layers 126, 128 may be sealed withsubstrate 120 using other means than adhesive, including lamination,heat sealing, and/or mechanical couplings. Further, in some embodiments,layers 126, 128 may be sealed or laminated to each other, rather than tosubstrate 120.

As shown, in various embodiments, adhesives 136, 138 may be disposedproximate first end 102 (and second end 104). In some embodiments,adhesives 136, 138 may be located at first end 102 (and second end 104),and in other embodiments, adhesives 136, 138 may be spaced apart fromfirst end 102 (and second end 104). In one embodiment, adhesives 136,138 may be spaced apart from first end 102 (and second end 104) by about1.5″, and adhesives 136, 138 may be about 2″ in width, though otherdimensions are contemplated.

However, in some example embodiments, first layer 126 of plastic filmand second layer 128 of plastic film are not sealed to substrate 120 atany location other than proximate ends 102 and 104. Thus, for instance,first layer 126 of plastic film and second layer 128 of plastic film arenot sealed to substrate 120 at either lateral edge 106, 108 (althoughthey may be secured to substrate 120 at or proximate these locationsafter a covering is formed from composite sheet 100, as described inmore detail below). As a result, each of first layer 126 and secondlayer 128 may define at least a portion of each layer that is slidablerelative to substrate 120 first surface 122 and second surface 124,respectively. In other words, at least the portions of each of firstlayer 126 and 128 that extend between the seals 136, 138 locatedproximate each end 102, 104 are movable relative to their correspondingfacing surfaces of substrate 120, rather than being laminated orotherwise sealed thereto. This is shown schematically in the enlargedcross-sectional view of FIG. 3 , wherein a semi-enclosed space 140 isdefined between substrate 120 and first layer 126, and a semi-enclosedspace 142 is defined between substrate 120 and second layer 128.

In various embodiments, having portions of first layer 126 and/or secondlayer 128 be “loose” or movable with respect to substrate 120 isadvantageous. For instance, it has been found that this structure, whenformed into a protective covering in accordance with embodiments of theinvention, provides padding and puncture resistance while alsopreventing abrasion of an object being transported. Correspondingly,where at least portions of these three layers can move relative to oneanother, it has been found that there is less likelihood that one ormore of the layers are rubbed through, particularly where the coveredobject is subject to vibration during transport.

Referring again to FIGS. 1-2 , as noted above, in some embodiments athird layer 134 of plastic film may be coupled with exterior surface 132of second layer 128. In various embodiments, third layer 134 may defineor comprise one or more plastic film end caps 144, 146. As describedherein, end caps 144, 146 may be used to further protect an object fromdamage and/or abrasion during transport. Thus, for example, end caps144, 146 may be coupled with second layer 128 in locations selected suchthat, when composite sheet 100 is formed into a protective cover, andthe cover is placed over an object, the end caps 144, 146 are disposedover portion(s) of the object that are most likely to be damaged duringtransport of the object.

Thus, depending on the type of object to be covered, and itscharacteristics and dimensions, the number and placement of end caps144, 146 may vary in various embodiments. For example, in someembodiments, only one end cap 144, 146 may be provided on one of panels112, 114, or across axis 110. In other embodiments, three or more endcaps could be provided. In some embodiments, rather than spanningportions of both panels 112, 114, each end cap 144, 146 may be entirelyon one respective panel 112, 114. Thus, end caps 144, 146 may havelongitudinal axes that are parallel with first end 102 and second end104 in some embodiments. The dimensions of and material selected foreach end cap 144, 146 on a single composite sheet 100 could also vary.

In the illustrated embodiment, end caps 144, 146 have longitudinal axesthat extend parallel with first and second ends 106, 108, and theypartially cover both panels 112, 114. Again, the size of third layer 134(and of end caps 144, 146) may vary in various embodiments, but in theillustrated embodiment end caps 144, 146 may have smaller peripheraldimensions than second layer 128. In particular, for a composite sheethaving peripheral dimensions of 110″ (along first and second lateraledges 106, 108) by 80″ (along first and second ends 102, 104), each endcap 144, 146 may be about 103″ in length (along first lateral edge 106and second lateral edge 108) and 24″ in width (along first end 102 andsecond end 104). Further, each end cap 144, 146 may be spaced apart fromfirst lateral edge 106 and second lateral edge 108 by about 10″ and maybe spaced apart from first end 102 and second end 104 by about 3.5″.Although end caps 144, 146 are shown positioned such that they arespaced apart from first end 102, second end 104, first lateral edge 106,and second lateral edge 108, in some embodiments, end caps 144, 146 mayextend up to or beyond any or all of first end 102, second end 104,first lateral edge 106, and second lateral edge 108.

Third layer 134 of plastic film may comprise a variety of materials andthicknesses within the scope of the present invention. In someembodiments, plastic film layer 134 may be or comprise polyethylenefilm, but that is not required in all embodiments. Further, in variousembodiments, third layer 134 may have a thickness (or equivalentthickness) between about 2 mil and 20 mil. Among other things, forexample, third layer 134 may be formed from polyethylene terephalate,polyurethane, and/or other plastic materials. In some exampleembodiments, third layer 134 may be analogous to surface protection tapehaving a thickness of about 12 mil. In other example embodiments, thirdlayer 134 may comprise fiberglass laminated with a plastic film.Further, in some example embodiments, third layer 134 may be analogousto protective films for electronic displays and the like. In still otherembodiments, third layer 134 need not be a plastic film layer at all. Inone embodiment, the third layer 134 may have a third thickness that isgreater than the thicknesses of first layer 126 and second layer 128. Inone embodiment, third layer 134 may have a thickness equivalent to 18mil polyethylene film.

Third layer 134 may be coupled with second layer 128 in a variety ofways known to those of skill in the art. In one embodiment, third layer134 is completely or partially laminated to second layer 128. In otherembodiments, third layer 134 may be coupled with second layer 128 via asuitable adhesive and/or a mechanical coupling. In contrast to thearrangement of first layer 126 and second layer 128 relative tosubstrate 120 in some embodiments, it is contemplated that in someembodiments third layer 134 may not be slidable or movable relative tosecond layer 128. Of course, in still other embodiments, it is possiblethat only certain portions of third layer 134 may be coupled with secondlayer 128, such as portions of third layer 134 proximate its periphery.

Turning now to FIGS. 4-5B, in various embodiments, composite sheet 100may be formed into a protective cover for an object, such as but notlimited to furniture, that is to be transported and handled. In thisregard, FIG. 4 is a plan view of composite sheet 100 wherein thecomposite sheet 100 has been folded about axis 110 according to anembodiment of the present invention. FIG. 5A is a front elevation viewof the composite sheet of FIG. 4 wherein portions of the foldedcomposite sheet have been spaced apart relative to one another to definean opening. FIG. 5B is an enlarged cross-sectional view taken along theline 5B-5B in FIG. 4 .

More particularly, and as best seen in FIG. 4 , in one embodiment,composite sheet 100 may be folded about axis 110 such that first end 102is aligned with second end 104. Likewise, the respective first andsecond lateral edges 106, 108 of the first and second panels 112, 114may be in alignment. As noted above, in other embodiments, axis 110 maynot be centered between ends 102, 104, and thus folding composite sheet100 about axis 110 in such embodiments may result in ends 102, 104 beingproximate, but not necessarily aligned. Likewise, depending on theorientation of axis 110 and the shape of composite sheet 100, afterfolding about axis 110, the respective first and second lateral edges106, 108 of first and second panels 112, 114 may not be in alignment inall embodiments. In still other embodiments, as noted above, panels 112,114 of composite sheet 100 may be separate in some embodiments, and assuch, panels 112, 114 may be placed into alignment without any foldingbeing required. In any case, and as described in more detail below,composite sheet 100 may be formed into a protective cover 200.

In this regard, to form protective cover 200 in one embodiment, aftercomposite sheet 100 has been folded about axis 110, first panel 112 maybe secured to second panel 114 (hidden in FIG. 4 ) in order to define apartially enclosed space 202 having an opening 204 (see FIGS. 5A-5B)proximate the first and second ends 102, 104 of the composite sheet 100.As shown, a first coupling 206 is located proximate the respective firstlateral edges 106 of panels 112, 114, and a second coupling 208 islocated proximate the respective second lateral edges 108 of panels 112,114.

First and second couplings 206, 208 may be any suitable couplingfamiliar to those of skill in the art. For instance, in variousembodiments, lamination, heat sealing, adhesives, and tapes are allcontemplated. In one example embodiment, first and second couplings 206,208 may comprise respective stitching 210, 212. In particular, firstpanel 112 may be sewed to second panel 114 at first and second couplings206, 208. Where first and second couplings 206, 208 comprise stitching210, 212, those of skill in the art are familiar with and can selectsuitable yarn or thread and a suitable pattern for the applicationsdiscussed herein. In one embodiment, the thread used for stitching 210,212 may comprise spun polyester or spun PET fibers.

As best seen in FIGS. 5A-5B, the stitching 210, 212 may extend througheach layer 128, 120, and 126 of each panel 112, 114 in one embodiment.Further, the stitching 210, 212 may extend along the entire lateral edge106, 108 dimensions in one embodiment, though in other embodiments, thestitching may terminate prior to ends 102, 104, or stitching may only bedone intermittently. One or more rows of stitching may be provided invarious embodiments; as shown, two rows of stitching are used on eachside of protective cover 200.

Additionally, in various embodiments, first and second couplings 206,208 may be located at respective first lateral edge 106 and secondlateral edge 108, or first and second couplings 206, 208 may be spacedapart from respective first lateral edge 106 and second lateral edge108. The illustrated embodiment includes the latter configuration. Thoseof skill in the art will appreciate that spacing couplings 206, 208apart from respective first lateral edge 106 and second lateral edge 108may facilitate assembly of protective cover 200 in some embodiments, inthat this arrangement makes it more likely that couplings 206, 208extend through each layer 128, 120, and 126 of each panel 112, 114. Thisarrangement may also provide advantages in terms of strength and/ordurability in some embodiments. In various embodiments, first and secondcouplings 206, 208 may be spaced apart from respective first lateraledge 106 and second lateral edge 108 by about 0.5″ to about 2″, thoughother distances are contemplated.

In various embodiments, the peripheral dimensions of protective cover200 may be selected such that the defined partially enclosed space 202may cover a given type of object, such as specific sizes or types offurniture. Thus, the peripheral dimensions of protective cover 200 willvary in various embodiments. In some example embodiments, the peripheraldimensions of protective cover 200 may be about 55″ (along lateral edges106, 108) by 80″ (along first and second ends 102, 104); about 55″(along lateral edges 106, 108) by 100″ (along first and second ends 102,104); about 55″ (along lateral edges 106, 108) by 120″ (along first andsecond ends 102, 104); about 55″ (along lateral edges 106, 108) by 140″(along first and second ends 102, 104); or about 55″ (along lateraledges 106, 108) by 160″ (along first and second ends 102, 104).

For instance, smaller protective covers 200 may be used to cover smallerpieces of furniture, such as small tables and chairs, whereas largerprotective covers 200 may be used to cover love seats, sofas, andsectionals. Again, though, protective covers 200 of any size needed ordesired are within the scope of the present invention. Notably, byproviding pre-made protective covers 200 of various predefined sizes topersonnel engaged in wrapping objects prior to transport, such personnelmay readily use the smallest bag that is adequate to cover and protect agiven object. This may save time and prevent wasted material. Further,in various embodiments, couplings 206, 208 may have predefined colorsthat correspond to the peripheral dimensions of protective cover 200.Such “color-coding” may serve as a visual indicator to personnel of thesize of a given protective cover 200.

FIGS. 6-9 show protective covers in use in accordance with variousembodiments of the present invention. In this regard, FIG. 6 is aperspective view of a protective cover 300 formed from a composite sheetin accordance with an embodiment of the present invention disposed abovea piece of furniture, e.g., couch 302. Protective cover 300, and thecomposite sheet from which it is formed, may be analogous to any of theembodiments described above. FIG. 6 shows protective cover 300 before itis used to cover couch 302. The panels 304, 306 of protective cover 300define an opening 308, and as indicated by arrow 310 in FIG. 6 , tocover couch 302, a user may lower protective cover 300 over couch 302such that couch 302 passes through opening 308 into the enclosed spacebetween panels 304, 306. FIG. 7 is a perspective view of the protectivecover 300 after it has been placed over couch 302 and secured in place,e.g., via tape or other adhesive. As shown, end caps 312, 314 aredisposed in locations such that they protect opposite ends of couch 302once protective cover is secured in place. This is because, for example,couches 302 are often stood on end during transport and handling, andthe opposite ends are most likely to suffer damage or abrasion duringsuch transport and handling. FIG. 8 is a perspective view of the bottomside of couch 302 covered with protective cover 300. As shown in FIG. 8, after protective cover 300 is placed over couch 302, protective cover300 may not completely cover the bottom side of couch 302. Rather, auser may tape the panels 304, 306 together and to couch 302 on thebottom side thereof. FIG. 9 is a perspective view of several differentobjects 316, 318, 320, 322 that have been covered with protective covers300 in accordance with an embodiment of the present invention. As shown,objects 316, 318, 320, and 322 have varying sizes, anddifferently-dimensioned protective covers 300 may be used to protecteach object.

Additionally, embodiments of the present invention provide methods ofmaking a protective cover. Various examples of the operations performedin accordance with embodiments of the present invention will now beprovided with reference to FIG. 10 .

FIG. 10 illustrates a flowchart according to example methods formanufacturing a protective cover according to an example embodiment. Theoperations illustrated in and described with respect to FIG. 10 may, forexample, be performed by a user of the protective cover, personnel thatwrap objects prior to transport, or by semi- or completely-automatedmachinery, either in whole or in part. In some embodiments, someoperations may be performed via machinery, and other operations may beperformed manually.

At operation 400, the process starts. At operation 402, a compositesheet is formed. In one embodiment the composite sheet is formed byproviding a substrate formed from a nonwoven material, the substratehaving a first surface and a second surface opposite the first surface;disposing a first layer of plastic film on the substrate first surface,wherein the first layer of plastic film has a first thickness; disposinga second layer of plastic film on the substrate second surface, whereinthe second layer of plastic film has a second thickness that is greaterthan the first thickness; and disposing at least one plastic film endcap on an exterior surface of the second layer of plastic film, whereinthe at least one plastic film end cap has a third thickness that isgreater than the first and second thicknesses. Additionally, in thisembodiment, the composite sheet has a first end, a second end, a firstlateral edge extending between the first and the second end, a secondlateral edge extending between the first end and the second end, and anaxis extending between the first lateral edge and the second lateraledge. At operation 404, the first layer of plastic film may be attachedto the substrate proximate the first end of the composite sheet andproximate the second end of the composite sheet. Similarly, at operation406, the second layer of plastic film may be attached to the substrateproximate the first end of the composite sheet and proximate the secondend of the composite sheet. In some embodiments, at least the secondlayer of plastic film may be corona-treated before or followingoperation 406.

In some embodiments, all or a portion of operations 402, 404, and/or 406may be performed via machinery. For instance, in some embodiments, thefirst layer of plastic film and the second layer of plastic film may bedisposed on the first and second surfaces of the substrate of nonwovenmaterial via a roll-to-roll process. In particular, during this process,a hot melt glue gun/dispenser may provide pressure sensitive adhesive(e.g., in a thin continuous or dotted line) on certain portions of thesubstrate of nonwoven material, the first layer of plastic film, and/orthe second layer of plastic film, and then these layers may be pressedtogether. As noted above, in various embodiments, the adhesive may beprovided only at select locations, such that portions of the layers ofplastic film are not adhered to the nonwoven substrate and are free tomove with respect thereto. In various other embodiments, any method ofsecuring the plastic film layers to the substrate of nonwoven materialfamiliar to those of skill in the art may be used, such as lamination,heat sealing, sonic welding, friction welding, and/or mechanicalfastening (such as by sewing).

At operation 408, the composite sheet may be folded about the axis suchthat the first end of the composite sheet is proximate the second end ofthe composite sheet. Then, at operation 410, the portion of thecomposite sheet extending between the first end and the axis may besecured to the portion of the composite sheet extending between thesecond end and the axis to define a partially enclosed space having anopening proximate the first and second ends of the composite sheet. Asnoted above, in some embodiments, operation 410 may comprise sewing oneportion of the composite sheet to the other portion of the compositesheet proximate the first and second lateral edges thereof. At operation412, the process ends.

Based on the foregoing, it will be appreciated that embodiments of theinvention provide improved protective covers and methods ofmanufacturing protective covers. Various embodiments provide protectivecovers that are abrasion and puncture resistant while also remainingflexible. Many modifications and other embodiments of the inventions setforth herein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Moreover, although the foregoing descriptions and the associateddrawings describe exemplary embodiments in the context of certainexemplary combinations of elements and/or functions, it should beappreciated that different combinations of elements and/or functions maybe provided by alternative embodiments without departing from the scopeof the appended claims. In this regard, for example, differentcombinations of elements and/or functions than those explicitlydescribed above are also contemplated as may be set forth in some of theappended claims. In cases where advantages, benefits or solutions toproblems are described herein, it should be appreciated that suchadvantages, benefits and/or solutions may be applicable to some exampleembodiments, but not necessarily all example embodiments. Thus, anyadvantages, benefits or solutions described herein should not be thoughtof as being critical, required or essential to all embodiments or tothat which is claimed herein. Although specific terms are employedherein, they are used in a generic and descriptive sense only and notfor purposes of limitation.

What is claimed is:
 1. A method of making a protective cover, the methodcomprising: forming a composite sheet by providing a substrate formedfrom a nonwoven material, the substrate having a first surface and asecond surface opposite the first surface; disposing a first layer ofplastic film on the substrate first surface; and disposing a secondlayer of plastic film on the substrate second surface; wherein thenonwoven material has a puncture resistance exceeding 500 N; wherein thecomposite sheet has a first end, a second end, a first lateral edgeextending between the first and the second end, a second lateral edgeextending between the first end and the second end, and an axisextending between the first lateral edge and the second lateral edge;folding the composite sheet about the axis to bring the first end of thecomposite sheet proximate the second end of the composite sheet anddefine a partially enclosed space having an opening proximate the firstand second ends of the composite sheet.
 2. The method of claim 1,wherein the second layer of plastic film is thicker than the first layerof plastic film.
 3. The method of claim 1, further comprising disposingat least one third layer of plastic film on an exterior surface of thesecond layer of plastic film.
 4. The method of claim 3, wherein the atleast one third layer of plastic film comprises two discrete layers ofplastic film each disposed on the exterior surface of the second layerof plastic film, and wherein the discrete layers of plastic film eachdefine a smaller surface area than the second layer of plastic film. 5.The method of claim 1, further comprising securing the lateral edges ofthe portion of the composite sheet extending between the first end andthe axis to the lateral edges of the portion of the composite sheetextending between the second end and the axis.
 6. The method of claim 1,wherein the nonwoven material has a puncture resistance exceeding 1000N.
 7. The method of claim 1, wherein the nonwoven material comprisesneedlepunched polyester fibers.
 8. A method of making a protectivecover, the method comprising: forming a composite sheet by providing asubstrate formed from a nonwoven material, the substrate having a firstsurface and a second surface opposite the first surface, wherein thenonwoven material has a puncture resistance exceeding 500 N; disposing afirst layer of plastic film on the substrate first surface, wherein thefirst layer of plastic film has a first thickness; disposing a secondlayer of plastic film on the substrate second surface, wherein thesecond layer of plastic film has a second thickness that is greater thanthe first thickness, and wherein the second layer of plastic film has athird surface in facing opposition with the substrate second surface anda fourth surface opposite the third surface; and disposing at least onethird layer of plastic film on the fourth surface of the second layer ofplastic film, wherein the at least one third layer of plastic film has athird thickness that is greater than the first and second thicknesses,and wherein the at least one third layer of plastic film has a fifthsurface in facing opposition with the fourth surface of the second layerof plastic film, the at least one third layer of plastic film defining asmaller surface area than the second layer of plastic film; wherein thecomposite sheet has a first end, a second end, a first lateral edgeextending between the first and the second end, a second lateral edgeextending between the first end and the second end, and an axisextending between the first lateral edge and the second lateral edge;folding the composite sheet about the axis such that the first end ofthe composite sheet is proximate the second end of the composite sheet;securing the portion of the composite sheet extending between the firstend and the axis to the portion of the composite sheet extending betweenthe second end and the axis to define a partially enclosed space havingan opening proximate the first and second ends of the composite sheet.9. The method of claim 8, further comprising attaching the first layerof plastic film to the substrate proximate the first end and the secondend of the composite sheet.
 10. The method of claim 9, wherein theattaching operation comprises applying pressure-sensitive adhesive. 11.The method of claim 8, wherein the securing operation comprises sewingthe composite sheet proximate the first and second lateral edgesthereof.
 12. The method of claim 8, further comprising corona-treatingthe second layer of plastic film.
 13. A method of making a protectivecover, the method comprising: forming a composite sheet by providing asubstrate formed from a nonwoven material, the substrate having a firstsurface and a second surface opposite the first surface, wherein thenonwoven material has a puncture resistance exceeding 500 N; disposing afirst layer of plastic film on the substrate first surface such that atleast a portion of the first layer of plastic film is slidable relativeto the substrate first surface; disposing a second layer of plastic filmon the substrate second surface such that at least a portion of thesecond layer of plastic film is slidable relative to the substratesecond surface, wherein the second layer of plastic film has a thirdsurface in facing opposition with the substrate second surface and afourth surface opposite the third surface; and disposing a third layerof plastic film on the fourth surface of the second layer of plasticfilm, the at least one third layer of plastic film defining a smallersurface area than the second layer of plastic film, wherein the thirdlayer of plastic film has a fifth surface in facing opposition with thefourth surface of the second layer of plastic film; wherein thecomposite sheet has a first end, a second end, a first lateral edgeextending between the first and the second end, a second lateral edgeextending between the first end and the second end, and an axisextending between the first lateral edge and the second lateral edge;folding the composite sheet about the axis to align the first end of thecomposite sheet with the second end of the composite sheet and define apartially enclosed space having an opening proximate the first andsecond ends of the composite sheet.
 14. The method of claim 13, furthercomprising sewing the portion of the composite sheet extending betweenthe first end and the axis to the portion of the composite sheetextending between the second end and the axis.
 15. The method of claim13, wherein, following the folding operation, the portion of the firstlayer of plastic film disposed on the portion of the composite sheetextending between the first end and the axis is in facing opposition tothe portion of the first layer of plastic film disposed on the portionof the composite sheet extending between the second end and the axis.16. The method of claim 15, wherein the first layer of plastic film hasa first thickness and the second layer of plastic film has a secondthickness, and wherein the first thickness is less than the secondthickness.
 17. The method of claim 16, wherein the third layer ofplastic film has a third thickness that is greater than the first andsecond thicknesses.
 18. The method of claim 17, wherein the third layerof plastic film is disposed on both the portion of the composite sheetextending between the first end and the axis and the portion of thecomposite sheet extending between the second end and the axis.